Apparatus for cutting and applying patches to window envelope blanks and like articles



g- 1961 R, WINKLER ET AL 2,996,952

APPARA FOR CUTTING AND APPLYING PATCHES TO WIND ENVELOPE BLANKS AND LIKEARTICLES Filed May 28, 1958 2 Sheets -Sheet l x *PEE Aug. 22, 1961 R.WINKLER ET AL 2,995,962

APP TUS FGR CUTTING AND APPLYING TCHES TO PA N OW ENVELOPE BLANKS ANDLIKE ARTICLES Filed May 28, 19 2 Sheets--Sheet 2 E A TTOR/VEY UnitedStates Patent 2,996,962 APPARATUS FOR CUTTING AND APPLYING PATCHES TWINDOW ENVELOPE BLANKS LIKE ARTKCLES Richard Winkler, Rengsdorf, nearNeuwied, and Kurt Dunnebier, Wollendorf, near Neuwied, Germany, as-.signors to Berkley Machine Company, Kansas City, Mo., a corporation ofMissouri Filed May 23, 1958, Ser. No. 745,521 Claims priority,application Germany June'7, 1957 6 Claims. (Cl. 93-61) This inventionrelates to an apparatus .for producing window envelopes and likearticles wherein a patch of thin sheet material is applied thereto.

.Eor example, in the manufacture .of window envelopes .a continuous webof thin transparentmaterial is fedfrom ;a roll to a severing mechanism,which cuts off patches from the web, and the patches are seized andcarried to .a transfer mechanism, which deposits the patches over theWindow openings of envelope blanks which are in motion in an envelopemaking machine.

Itis obvious that the timing and action of such mechanisms is criticalin order that the patches may be of exact size and located accuratelyover the window openings, and particularly relatively to the adhesivethat has been previously applied to the blanks for securing the patches,but prior to the present invention such mechanisms have not beencompletely satisfactory and loose edges are left at the margins of thepatches.

The transparent material usually employed is paper, cellophane,parchment, or the like, and is very thin, easy to curl and difficult tohold, with the result that the detached pieces are often cutinaccurately and they slip during transfer, with the result that theyare inaccurately placed on the envelope blanks.

The patches are usually cut so-that they extend beyond the outer edgesof the adhesive to assure coverage of the adhesive and prevent exudingof the adhesive from the outer edges of the patch. This extra amount ofpatch material results in considerable waste over a period of time.

It is, therefore, the principal object of the present invention toprovide an improved apparatus which cuts the patches with accuracy andtransfers them without slipplug in exactly timed relation with movementof the envelope blanks.

Other objects of the invention are to providemeans for seizing andsecurely holding the end of the web under tension while the patchcutting mechanism is in operation; to provide for a continuous hold onthe cut off patch while it is being removed from the cutting mechanism;to provide transfer mechanism with means for gripping the patch andpulling it from the removing means, and to provide the transfermechanism with means for gripping and holding the patch while it isbeing carried to the place of deposit on a moving envelope blank.

Further objects of the invention are to provide a simple apparatus forcutting and applying the patches in their correct position without anyspecial attention on the part of "the operator of the envelope makingmachine, and to provide patches that are accurately cut to size andneonrately applied over the'adhesive, thereby eliminating loose edgesand permitting'use of smaller patches.

In accomplishing these and otherobjects of the invention, we haveprovided improved structure, the preferred form of which is illustratedin the accompanying drawings, wherein:

FIG. 1 is a longitudinal vertical section through a patch applyingapparatus embodying the features of .the present invention.

'FIG. 2 is an enlarged diagrammatic section to better illustrate controland holding of the patches.

FIG. 3 is a fragmentary section showing adjustment of the counterrollerfor larger size patches.

FIG. 4 is a perspective view of aportion of an envelope blank with thepatch applied over the window opening.

Referring more in detail to the drawings:

1 designates a preferred embodiment of the apparatus for applying, forexample, thin, transparent patches A .in covering relation with theWindow openings B in blanks C (FIG. 1) from which window envelopes areformed while the blanks are in motion in an envelope making machinerepresented by the cylinder 2.

The apparatus 1 includes a feeding mechanism 3 for feeding the patchmaterial to a cutoff mechanism 4 for cutting the patches A, a mechanism5 for removing the cut off patches from the cutting mechanism, and atrans-'- fer mechanism 6 for taking the patches from the removingmechanism 5 and applying the patches to the envelope blanks C as theyare carried around the cylinder 2 of the envelope making machine.

The patch material may be paper, transparent paper, cellophane,parchment, or the like. The material is thin and for convenience iscontained in a roll 7 in the .form

of a web 8 having a Width corresponding to one dimen- =sion of thepatches A to be formed therefrom. The roll 7 and the mechanisms of theapparatus are suitably supported by side frames 9 that may be carried onthefr-ame of the envelope making machine in a suitable positionrelatively to the cylinder 2.

The feeding mechanism 3' includes upper and lower continuously rotatingfeed rollers 10 and 11 between which the web 8 is passed (FIG. 1). Thelower feed roller 11 is preferably the driving roller, over which theweb passes when pressed into contact therewith by the upper roller 10.The upper feed roller 10 is preferably 'journaled in bearings 12 thatare movable in ways 13 of the side frames 9 under action of springs 14to maintain a frictional contact of the web 8 with the driving roller.11 to withdraw the web from the roll 7 and pass it be tween upper andlower guides 15 and 16 to the cutoff mechanism 4.

The cutoff mechanism 4 includes a stationary knife element 17 that iscarried transversely of the path of the web 8 on a cross bar '18 carriedbetween the side frames 9. The cutoff mechanism 4 also includes amovable cutting element 19 in the form of a blade 20 that is carried in.a recess 21 of a rotor 22. The rotor 22 is rotatably mountedtransversely below the path of the web 8 and in position so that uponeach revolution the blade 20 comes into shearing contact with thestationary knife element 17. The side of the rotor 22 opposite the knifeblade 20 has a recess or flat side 23 to facilitate movement of the endof the Web after a cut has been made through the web to form a patch A,as later described.

The rotor 22 of the cutoff mechanism is' operated at a speed relativelyto the feed rollers 10 and H. to feed a .predetermined length of the webupon each revolution of the rotor to constitute the other dimension ofthe patch. The speed regulating means is not shown in the drawing, .butmay be of any Well known type whereby the timing of the feed rollers 10and 11 and the rotor 22 may be changed to obtain patches A of desiredlength to conform with various sizes of the openings B in the envelopeblanks that are under manufacture in the envelope making machine. Thecut off patch A is supported on the periphery of the rotor 22 and passesfreely under an arcuate guide 24 to the patch removing mechanism 5.

The patch removing mechanism includes a suction roller 25 which ispreferably made up of a plurality of disks mounted on a transverse shaft26, whereby the number and position of the disks may be adjusted toconform with the width of the patches A. The shaft 26 is rotatablymounted insuitable journals in the side frame and in position where- 3by the peripheral face 27 of the suction roller 25 travels insufficiently spaced relation with the peripheral face 28 of the rotor 22to carry the patch A therebetween. The disks are provided with radialopenings or nozzles 29 that are arranged in spaced relation around theirperiphery, with the openings 29 in one disk adapted to align laterallywith those of the adjacent disks to form transverse rows of the openings29 along the length of the suction roller. Suction is drawn through theopenings or nozzles 29 by way of channels 30 which, as the suctionroller 25 rotates in the direction of the arrow (FIG. 1) are adapted tocome into registry with a vacuum chamber or manifold 31 at one endthereof and which is connected with a suitable source of vacuum (notshown). The vacuum chamber 31 may be of arcuate shape and is supportedbelow the shaft 26 of the suction roller 25 whereby, as the roller 25rotates in correspondence with the speed of the knife rotor 22 of thecutoff mechanism, a suction is drawn through one or more rows of theopenings 29 to engage the free end of the web 8 and to hold the web intension just prior to and while the blade is cutting through the web,thereby assuring the proper length of a patch and preventing anydisplacement or wavering thereof. Continuing rotation of the suctionroller draws the patch from the rotor 22, and as the succeeding rows ofsuction openings 29 come into registry with the suction manifold 31,they are made eifective in seizing the cut off patch closely against thearcuate face 27 of the suction roller 25 and thereby hold the patch insmooth contact, free of wrinkles and curls. The suction roller 25carries the patches A through an arcuate pass 32 that is formed betweenthe lower periphcry of the suction roller 25 and arcuate guides 33, the

guides 33 being carried on a transverse rod 34. The

The transfer mechanism 6 includes a pair of rollers 35 and 36, of whichthe roller 36 is a suction roller and the roller 35 is a pressure orcounter-roller yieldingly retained in contact with the periphery 37 ofthe suction roller 36 by springs 38 that press against bearing blocks 39which journal the ends of the roller 35 in a frame 40, by which theposition of the roller 37 is adjusted about the upper periphery of thesuction roller 36.

The suction roller 36 is of larger diameter than the suction rollerpreviously described and has, for example,

two parallel rows 41 and 42 of openings or nozzles that respectivelyconnect with suction ducts 43 and 44. The suction roller 36 may be madeup of a series of disks similar to the suction roller, with the disksbeing mounted on a transverse shaft 45 that is journaled in the sideframes 9 and driven at a speed to provide a peripheral speed greaterthan the peripheral speed of the suction roller 25 and in the directionof the arrow (FIG. l). The suction roller 36 on the advance side of therows of openings 41 has a transverse recess or groove 46 which forms agripping edge 47 that cooperates with the pressure roller 35 in pullingthe patches A from the suction roller 25 by gripping the forward edgesof the patches therebetween. Since the gripping edge 47 is to engage theforward marginal edge of the patches, the pressure or counter-roller 38must be positioned according to the size of the patch. This adjustmentis accomplished through the frame 40, as now to be described. The frame40 includes side members 48 that are journaled in bearings 49 on theside frames 9 that journal the shaft 45. The sides 48 of the frame 40have depending arms 50 connected by a bar 51. The sides of the frameextend above the periphery of the suction roller to carry the bearingblocks 39 for the shaft of the roller 35. The extensions are alsoconnected by a transverse bar 51' similar to the arms 50.

The frame 40 carries an arcuate segment 52 on one of the sides 48 whichmeshes with a gear 53. The gear 53 is fixed to a shaft 54. When theshaft 54 is turned in a counterclockwise direction (FIG. 1) the gear 53rocks the frame 40 on the axis of the shaft 45 to move the roller 35 asshown in FIG. 3 to provide for handling a larger sized patch than thatshown in FIG. 1.

The patch, when attached to the peripheral face of the roller 36 iscarried to the applicating position on the cylinder 2 through a pass 55that is provided between the face 37 of the roller 36 and arcuate guiderails 56 carried on a transverse bar 57. It is obvious that the suctionroller 25 being positioned between the rotary cutting member and thepatch applying roller 36, the cylindrical surface thereof provides asubstantially tangential transfer point with the rotary cutting memberon one side and a substantially tangential transfer point with the patchapplying roller 36 on the other side, and that the source of suction onthe patch is from near the tangential transfer point with the rotarycutting member to near the tangential transfer point wtih respect to thepatch applying roller, whereby a continuous hold is maintained on thepatch until the leading edge of the patch is firmly gripped between thepressure roller 35 and the gripping edge 47 of the applicating roller36.

In using the apparatus constructed and assembled in connection with anenvelope making machine as described, the Web 8 is drawn from the roll 7and threaded between the feed rollers 10 and 11 so that it is grippedtherebetween with the free end contained between the guides 15 and 16.The various driven shafts of the apparatus are connected in drivingrelation with the envelope making machine, so that the envelope blanks Care delivered by the cylinder 2 in timed relation with operation of thevarious mechanisms of the apparatus 1. The blanks are delivered to thecylinder '2 with the gum applied around the window opening B asindicated at D, FIG. 4, and ready to receive a patch thereon.

When the cutting rotor 22 moves in the direction of the arrow (FIG. 1),the cutting edge of the blade 20 moves away from the cutting edge of thefixed cutting element 17 and the feed rollers 10 and 11 move the webtherebetween until the cutting edge of the blade 20 again comes intoposition to sever the web and provide a patch of proper size.

As previously stated, the size of the patch A is dependent upon the sizeof the window opening B of the blank and the width of the gum appliedtherearound so that the edges of the patches will register with outeredges of the adhesive. The size of the patch is regulated by using a webof certain width and by adjusting the speed of the feed rollers 10 and11 relative to the speed of the rotor 22 to feed the desired amount ofmaterial by the time the rotatably carried cutotf blade 20 reaches thefixed cutoff element 17. The pressure or counter-roller 35 is adjustedfor the size of the patch by turning the shaft 54 in the properdirection.

Just prior to the cutoff, one or more rows of the openings 29 in thesuction roller 25 have engaged the free end of the web and drawn ittautly over the face 28 of the rotor, so that an accurate cut is madeacross the web. With continued rotation of the suction roller, other ofthe rows of openings 29 come into position to effect engagement of thepatch, so that when the patch has been completely removed from thecutting mechanism, it is held firmly in fiat contact with the peripheralface of the suction roller while it is being moved through the pass 32(FIG. 2). With continued movement of the suction roller in the directionof the arrow (FIG. 1), the forward edge of the patch moves upwardlybetween the suction roller 25 and the face 37 of the larger suctionroller 36 of the transfer mechanism into the pass 55. The feed of thepatch into the pass 55 is augmented by force which is produced by theroller 36 operating at a higher speed than the roller. 25 to bring theleading edge of the patch into contact with the pressure roller 35 to beengaged by thegripping edge 41. By this time the first row of suctionopenings 41 have reached the leading marginal edge portion of the patchand the suction may be made effective through those openings. Duringthis advance of the patch, the suction is cut off from the rows ofopenings of the suction roller as the channels therefor move out ofregistry with the suction chamber 31. The pressure roller is set so thatwhen the leading edge of the .patch is engaged between ,the roller 35and the gripping .edge 47 of the roller ,36, the trailing marginal edgeof the patch has just about cleared the last of the open- .ings 29 thatare then effective in the suction roller 25.

Atthis point, suction is also made efiective through the row of openings42, so that the forward and trailing marginal edges of the patch aredrawn to the roller 36 to hold the patch smoothly thereon as the patchis pulled off the roller 25. The larger suction roller now carries thepatch at a higher rotational speed and brings it into position where itis deposited over the gum D that has been applied around the windowopening B of the blank ,C that is then in position on the cylinder 2.During application of the patch the suction through the series of holes4-1 and 42 is relieved in proper sequence by time actuated valving meansof the usual type, similar to the suction control forthe suction roller25.

It is obvious that the patch is held by the suction roller 25 at thetime of the cut, so that the cut patch is accurately formed, and thatthe suctionrollers maintain aconst-ant ho ld jQn the patch to keep thepatch taut and free of puckers. After transfer of the patch from the.suction roller '25 to the patch applying roller 36, it is held tightlyagainst the peripheral face thereof to be rolled onto the envelope blankC and pressed into con-- tact with the sealing gum 'D.

When a different size patch is needed, the relative speed between thecutting roller .19 and the feed rollers '10 and 1-1 is changed and theposition of the pressure roller 35 is changed, so that just prior to thetime the trailing edge ofthe patch is transferred to the transfer roller36, the forward edge of the larger patch is gripped between the grippingledge 47 and the pressure roller 35. It is obvious that vafteradjustment of the pressure roller 35, the patch of different size ispulled from the roller 25 without {slipping of the patch on the roller36, in the same manner as previously described.

What we claim and desire to secure'by 'Letters Patent 1s:

1. An apparatus for cutting patches of thin sheet martcrial and carryingthe patches into applicating contact with envelope blanks, saidapparatus including a fixed cutting'element and a rotary cuttingelement, means for feeding a web of said material in continuous movementbetween the fixed and rotary cutting elements, a continuously rotatingpatch applying roller having a substantially continuous cylindricalsurface spaced from the rotary cutting member and having a portionthereof prowiding a gripping edge, a continuouslyrotating suction rollerintermediate the rotary cutting element and the patch applying rollerand having a cylindrical surface providing a substantially tangentialtransfer point with the rotary cutting element on one side and asubstantially tangential transfer point with the patch applying rolleron the other side, said patch applying roller having a faster surfacespeed than the surface speed of the suction roller, means associatedwith the suction roller for establishing a continuous source of suctionon the patch from near the tangential transfer point of the rotarycutting element to near the tangential transfer point of the patchapplying roller for applying suction to the free end of the webextending over the rotary cutting element to seize and tension the webduring cutting through of the web to provide a patch and fortransferring the patch progressively into contact with the patchapplying roller and progressively releasing the leading portion of thepatch at the tangential transfer point with the patch applying roller, apressure roller, and means supporting the pressure roller in rollingcontact with the cylindrical surface of said patch applying roller tocooperate with said gripping edge to grip and time theleading edge ofthe patch when the trailing edge of the patch is still being held bysuction, said patch applying roller having suction means for seizing the.patch to cooperate with the pressure roller and gripping edge to .drawsaid patch from the suction roller without slipping of the patch and tocarry the patch into contact with an envelope blank.

2. An apparatus for cutting patches of thin sheet material and carryingthe patches into applicating contact with envelope blanks, saidapparatus including a fixed cutting element and a rotary cuttingelement, means for feeding a'web in continuous movement of said mate-,rial between the fixed and rotary cutting elements, a continuouslyrotatable patch applying roller having a substantially continuouscylindrical surface spaced from the rotary cutting member and having aportion thereof providing a gripping edge, a continuously rotatablesuction roller intermediate the rotary cutting element and the patchapplying roller and having a cylindrical surface providing asubstantially tangential transfer point with the rotary cutting elementon one side and a substantially tangential transfer point with the patchapplying roller on the other side, said patch applying roller having afaster surface speed than the surface speed of the suction roller, meansassociated with the suction roller for establishing a continuous sourceof suction on the patch from near the tangential transfer point of therotary cut ting element to near the tangential transfer point of thepatch applying roller for applying suction to the free end of the webextending over the rotary cutting element to seize and tension the webduring cutting through of the web to provide a patch and fortransferring the patch progressively into contact with the patchapplying roller and progressively releasing the leading portion of the.patch at the tangential transfer point with the patch applying roller,a pressure roller, and means supporting the pressure roller in rollingcontact with the cylindrical surface of said patch applying roller tocooperate with said gripping edge to grip and time the leading edge ofthe patch when the trailing edge of the patch is still being held bysuction, said patch applying roller having suction ports for seizing theleading and trailing mar- :gi al portions of the patch to cooperate withthe pressure roller and gripping edge to draw said patch from contactwith the suction roller without slipping of the :patch and to carry thepatch into contact with an envelope blank.

3. An apparatus for cutting patches of thin sheet material and carryingthe patches into applicating contact with envelope blanks, saidapparatus including a fixed cutting element and a rotary cuttingelement, means for feeding a web of said material between the fixed androtary cutting elements, a patch applying roller having a substantiallycontinuous cylindrical surface spaced from the rotary cutting member andhaving a portion thereof providing a gripping edge, a suction rollerintermediate the rotary cutting element and the patch applying rollerand having a cylindrical surface providing a substantially tangentialtransfer point with the rotary cutting element on one side and asubstantially tangential transfer point with the patch applying rolleron the other side, means associated with the suction roller forestablishing a continuous source of suction on the patch from near thetangential transfer point of the rotary cutting element to near thetangential transfer point of the patch applying roller for applyingsuction to the free end of the web extending over the rotary cuttingelement to seize and tension the web during cutting through of the webto provide a patch and for transferring the patch pro gressively intocontact with the patch applying roller and progressively releasing theleading portion of the patch at the tangential transfer point with thepatch applying roller, a pressure roller, a frame member for carryingthe pressure roller, and means supporting the frame member for rockingsupport about the rotational axis of the patch applying roller to adjustthe position of the pressure roller from the tangential transfer pointof the suction roller for timing grip of the leading edge of the patchby said gripping edge when the trailing edge of the patch is still beingheld by the suction roller, said patch applying roller having suctionports for seizing the leading and trailing marginal portions of thepatch to cooperate with the pressure roller and gripping edge in drawingsaid patch from the suction roller without slipping of the patch and tocarry the patch into timed con- -tact with an envelope blank.

' 4. An apparatus as described in claim 3 for cutting and carryingpatches into applicating contact with envelope blanks, and including atoothed segment on the frame member and a gear meshing with the teeth ofthe segment for rocking the frame member to adjust the position of thepressure roller.

5. An apparatus for cutting patches of thin sheet material and carryingthe patches into applicating contact with envelope blanks, saidapparatus including a fixed cutting element and a rotary cuttingelement, means for feeding a web of said material continuously betweenthe fixed and rotary cutting elements, a continuously rotatable patchapplying roller having a substantially continuous cylindrical surfacespaced from the rotary cutting member and having a transverse grooveproviding a gripping edge, a continuously rotatable suction rollerintermediate the rotary cutting element and the patch applying rollerand having a cylindrical surface providing a substantially tangentialtransfer point with the rotary cutting element on one side and asubstantially tangential transfer point with the patch applying rolleron the other side, said suction roller having ports arranged in spacedrelation about the periphery thereof, means for establishing acontinuous source of suction through the ports extending from near thetangential transfer point of the rotary cutting element to near thetangential transfer point of the patch applying roller to apply suctionto the free end of the web extending over the rotary cutting element toseize and tension the web during cutting through of the web to provide apatch and to transfer the 'patch onto the suction roller progressivelywith movement of the ports into connection with the said suction 'supplymeans for taking the patch from the rotary cutting means and holding thepatch on the cylindrical surface of the suction roller while the suctionroller 'is carrying the leading edge of the patch into contact with thepatch applying roller and progressively releasing the leading portion ofthe patch as the ports pass out of connection with said suction supplymeans, a pressure roller, and means supporting the pressure roller inrolling contact with the cylindrical surface of said patch applyingroller to cooperate with said gripping edge to grip the leading edge ofthe patch when the trailing-edge of the patch is still being held bysuction, said patch applying roller having suction ports for seizing thepatch to cooperate with the pressure roller and gripping edge to drawsaid patch from contact with the suction roller without slipping of thepatch and to carry the patch into contact with an envelope blank.

6. An apparatus for cutting patches of thin sheet material and carryingthe patches into applicating contact with envelope blanks, saidapparatus including a rotary cutting element, a cutting elementcooperating with the rotary cutting element, means for feeding a web ofsheet material in continuous movement between said cutting elements, acontinuously rotatable patch applying roller having a substantiallycontinuous cylindrical surface spaced from the rotary cutting elementand having a portion thereof providing a transverse gripping edge, acontinuously rotatable suction roller intermediate the rotary cuttingelement and the patch applying roller and having a cylindrical surfaceproviding a substantially tangential transfer point with the rotarycutting element on one side and a substantially tangential transferpoint with the patch applying roller spaced from said first namedtangential transfer point, means associated with the suction roller forestablishing a continuous source of vacuum on the patch near thetangential transfer point of the rotary cutting element to near thetangential transfer point of the patch applying roller for applyingsuction to the free end of the web extending over the rotary cuttingelement to seize and tension the web during cutting through of the webto provide a patch and for transferring the patch progressively intocontact with the patch applying roller and progressively releasing theleading portion of the patch at the tangential transfer point with thepatch applying roller, a pressure roller, a frame member for carryingthe pressure roller, and means supporting the frame member for rockingsupport about the rotational axis of the patch applying roller to adjustthe position of the pressure roller from the tangential transfer pointof the suction roller with said patch applying roller for timing grip ofthe leading edge of the patch by said gripping edge, said patch applyingroller having suction ports for seizing portions of the patch tocooperate with the pressure roller in holding the patch and to carry thepatch into timed contact with an envelope blank.

References Cited in the file of this patent UNITED STATES PATENTS1,933,121 Rife Oct. 31,1933 2,070,205 Heywood Feb. 9; 1937 2,167,005Sauerman July 25; 1939 32,206,043 Novick July 2, 1940 2,209,347 NovickJuly 30, 1940 2,209,348 Novick July 30, 1940 2,254,217 Grupe Sept. 2,1941 2,543,220 Ardell Feb. 27, 1951 2,703,043 Novick et al t. Mar. 1,1955

